Lamination apparatus and methods

ABSTRACT

Components for the manufacture of polymer electrolyte membrane fuel cells are provided, as well as apparatus and automatable methods for their manufacture by rotary die cutting and by lamination of various layers to form membrane electrode assemblies. A method and apparatus for performing the method are provided for making a membrane electrode assembly comprising the steps of providing a web of polymer electrolyte membrane material and a laminating station, where the web of polymer electrolyte membrane material is drawn between a pair of laminating rollers in the laminating station which form a laminating nip; die-cutting a first and second web of catalyst decal materials or electrode materials to make first and second workpieces at first and second rotary die stations; which typically have a shape other than a four-sided parallelogram; holding the die-cut workpieces by action of sub-ambient air pressure to an endless perforated belt of first and second vacuum conveyors, typically before they are fully cut from the first and second webs; transporting first and second workpieces to opposing sides of the membrane in the laminating station; concurrently feeding the first and second workpieces into the laminating nip adjacent to the membrane, typically before they are fully released by the first and second vacuum conveyors; and laminating the first and second workpieces to the membrane, advantageously in accurate registration.

FIELD OF THE INVENTION

[0001] This invention relates to components for the manufacture ofpolymer electrolyte membrane fuel cells and apparatus and automatablemethods for their manufacture by lamination of various layers to formmembrane electrode assemblies.

BACKGROUND OF THE INVENTION

[0002] U.S. Pats. Nos. 6,159,327, 6,007,660 and 5,783,024 disclose anapparatus and method for making a plurality of substrates laminated onone or two sides with scissor-cut sheets of laminate.

SUMMARY OF THE INVENTION

[0003] Briefly, the present invention provides a method for making amembrane electrode assembly comprising the steps of providing a web ofpolymer electrolyte membrane material and a laminating station, wherethe web of polymer electrolyte membrane material is drawn between a pairof laminating rollers in the laminating station which form a laminatingnip; die-cutting a first and second web of catalyst decal materials orelectrode materials to make first and second workpieces at first andsecond rotary die stations; holding the die-cut workpieces by action ofsub-ambient air pressure to an endless perforated belt of first andsecond vacuum conveyors, typically before they are fully cut from thefirst and second webs; transporting first and second workpieces toopposing sides of the membrane in the laminating station; concurrentlyfeeding the first and second workpieces into the laminating nip adjacentto the membrane, typically before they are fully released by the firstand second vacuum conveyors; and laminating the first and secondworkpieces to the membrane, advantageously in accurate registration.

[0004] In another aspect, the present invention provides an apparatusfor making a membrane electrode assembly comprising a laminationstation; a first and second vacuum conveyor; and a first and secondrotary die station. These five components may be situated and gearedtogether so that first and second workpieces emerging from first andsecond rotary die stations are held by action of sub-ambient airpressure to the endless perforated belt of first and second vacuumconveyors before they are fully cut from the first and second webs andare fed into the laminating nip adjacent to the membrane before they arereleased by the vacuum conveyors.

[0005] In another aspect, the present invention provides a membranecomprising a plurality of membrane electrode assemblies, which comprisesa polymer electrolyte membrane having a first and second face; aplurality of first patterned catalyst layer segments or electrodeslaminated on the first face of the membrane such that adjacent patternedcatalyst layer segments are not in contact with each other; and aplurality of second patterned catalyst layer segments or electrodeslaminated on the second face of the membrane such that adjacentpatterned catalyst layer segments are not in contact with each other.Typically the first patterned catalyst layer segments or electrodes arein accurate registration with the second patterned catalyst layersegments or electrodes. Typically each of said first and secondpatterned catalyst layer segments or electrodes have a perimeter whichis a shape other than a four-sided parallelogram. The first catalystlayer segments or electrodes may have a catalyst composition thatdiffers from the catalyst composition of the second catalyst layersegments or electrodes.

[0006] In another aspect, the present invention provides a die-cutcatalyst decal or electrode which has a perimeter which is a shape otherthan a four-sided parallelogram, typically made by a method of rotarydie cutting.

[0007] In this application:

[0008] “to laminate” means to bond together two or more sheet materials;and

[0009] “membrane electrode assembly” means a construction comprising atleast three layers, including a catalyst layer, a layer of a polymerelectrolyte membrane, and another catalyst layer, and which may alsocomprise five layers, including a fluid transport layer, a catalystlayer, a layer of a polymer electrolyte membrane, another catalystlayer, and another fluid transport layer; and

[0010] “fluid transport layers” may include layers previously termed“diffuser/current collector” (DCC) layers, “gas diffusion layers” (GDL),or “electrode backing layers” (EBL's).

[0011] It is an advantage of the present invention to provide methods,apparatus, and components for the manufacture of polymer electrolytemembrane fuel cells.

BRIEF DESCRIPTION OF THE DRAWING

[0012]FIGS. 1 and 2 illustrate two views of an apparatus according tothe present invention.

DETAILED DESCRIPTION OF PREFERRED EMBODIMENT

[0013] With reference to FIGS. 1 and 2, an apparatus according to thepresent invention comprises a pair of rotary die stations 10, 20, a pairof angled vacuum conveyors 30, 40, and a lamination station 50. Angledvacuum conveyors 30, 40 may be the vacuum conveyors described inco-pending U.S. patent application ______, titled “Angled ProductTransfer Conveyor,” filed on even date herewith. Each combination of diestation and angled vacuum conveyor, 10 with 30 and 20 with 40, maycomprise the apparatus for cutting and transporting sheet materialsdescribed in co-pending U.S. patent application ______, titled “AngledProduct Transfer Conveyor,” filed on even date herewith. Laminationstation 50 may comprise the gapping block and other lamination apparatusdescribed in co-pending U.S. patent application ______, titled “GapAdjuster for Laminating Rolls,” filed on even date herewith.

[0014] Any suitable rotary die station may be used. Each rotary diestation 10, 20 comprises a rotary die 60, anvil roll 70 rotatablyattached to a frame comprising frame elements 80. One or both of rotarydie 60 and anvil roll 70 are driven. Rotary die 60 and anvil roll 70 aretypically geared together by electronic or mechanical gearing. In theapparatus as depicted, anvil roll 70 is driven by servo motor 90 andmechanically geared to rotary die 60. Any suitable combination of rotarydie 60 and anvil roll 70 may be employed. Rotary die 60 typicallycomprises a cutting edge or edges (not apparent in FIGS. 1 and 2)wrapped around the outer portion of a roller having a suitable depth forthe material to be cut. Unlike simple chopping or scissoring apparatus,which can produce workpieces having a shape selected from the set offour-sided parallelograms, rotary die 60 can produce cut workpieces 100of arbitrary shape, including curved portions such as rounded corners,from a continuous web (not shown). Typical die-cut shapes have roundedcorners, due to the limitations of die machining, and are therefore notfour-sided parallelograms. The continuous web and cut workpieces 100 maybe of any suitable material to be laminated to membrane 110.

[0015] In one embodiment according to the present invention, useful inthe manufacture of membrane electrode assemblies for fuel cells,workpieces 100 are catalyst decals comprising a liner layer and aco-extensive catalyst layer which comprises particulate catalyst metal.Such workpieces are cut from a continuous web of the liner layer coatedwith the catalyst layer on at least a portion passing under the cuttingportion of rotary die 60. Any suitable liner may be used, including anysuitably flexible polymeric sheet materials having a thickness oftypically less than 1 millimeter, more typically less than 0.5millimeter, and more typically less than 0.2 millimeter. The catalystlayer may be applied by any suitable method, including bar coating,spray coating, slit coating, brush coating, and the like. The catalystlayer typically has a thickness of less than 1 millimeter, moretypically less than 0.5 millimeter, and more typically less than 0.2millimeter. Any suitable catalyst composition may be used. Typicalcatalyst compositions fine particles of platinum, palladium, rutheniumand other catalyst metals, or combinations of catalyst metals, supportedon carbon particles. The carbon-supported catalyst particles aretypically 50-60% carbon and 40-50% catalyst metal by weight, thecatalyst metal typically comprising Pt for the cathode and Pt and Ru ina weight ratio of 2:1 for the anode. Typical catalyst compositions mayalso include polymer electrolyte materials such as sulfonatedfluoropolymers, including Nafion™ or Flemion™. After the catalyst decalis laminated the liner is typically removed.

[0016] In another embodiment according to the present invention, alsouseful in the manufacture of membrane electrode assemblies for fuelcells, workpieces 100 are electrodes comprising a fluid transport layerand a co-extensive catalyst layer which comprises particulate catalystmetal. Such workpieces are cut from a continuous web of the fluidtransport layer coated with the catalyst layer on at least a portionpassing under the cutting portion of rotary die 60. Any suitable fluidtransport layer may be used. Suitable fluid transport layers for fuelcell use are porous, to allow passage of fluids, and electricallyconductive. Typical fluid transport layers include carbon fiber fabrics,mats, non-wovens and papers, such as Toray Carbon Paper (TorayIndustries, Inc., Tokyo, Japan). The catalyst layer may be applied byany suitable method, including bar coating, spray coating, slit coating,brush coating, and the like. Any suitable catalyst composition may beused. Typical catalyst compositions fine particles of platinum,palladium, ruthenium and other catalyst metals, or combinations ofcatalyst metals, supported on carbon particles. The carbon-supportedcatalyst particles are typically 50-60% carbon and 40-50% catalyst metalby weight, the catalyst metal typically comprising Pt for the cathodeand Pt and Ru in a weight ratio of 2:1 for the anode. Typical catalystcompositions may also include polymer electrolyte materials such assulfonated fluoropolymers, including Nafion™ or Flemion™. Prior tocoating with the catalyst dispersion, the gas diffusion layer hastypically been coated with a hydrophobic layer such as Teflon™,typically by dipping in an aqueous suspension thereof, and then hastypically been coated with a carbon black dispersion. The carbon blackdispersion is typically an aqueous dispersion comprising carbon blackand Teflon and optionally a surfactant such as TRITON X-100 (UnionCarbide Corp., Danbury, Conn.). More typically, the dispersant is acombination of water and isopropyl alcohol, typically comprising morethan 60% by weight isopropyl alcohol. The carbon black dispersion istypically coated onto the dried Toray paper at a wet thickness of 0.01to 0.1 mm. The Teflon and carbon black coated fluid transport layer istypically dried in an oven at 380° C. for 10 minutes. This coated fluidtransport layer is then further coated with the catalyst, typically inan amount yielding 0.2-5 mg of catalyst metal (Pt or Pt plus Ru) persquare centimeter, typically about 0.5 mg of catalyst metal (Pt or Ptplus Ru) per square centimeter, to form a catalyst-coated fluidtransport layer.

[0017] In embodiments according to the present invention useful in themanufacture of membrane electrode assemblies for fuel cells, membrane110 is a polymer electrolyte membrane, such as a sulfonatedfluoropolymer membrane, such as Nafion® (DuPont Chemicals, WilmingtonDel.) and Flemion™ (Asahi Glass Co. Ltd., Tokyo, Japan). The polymerelectrolytes useful in the present invention are typically copolymers oftetrafluoroethylene and one or more fluorinated, acid-functionalcomonomers, typically bearing sulfonate functional groups. Mosttypically the polymer electrolyte is Nafion®. The polymer electrolytetypically has an acid equivalent weight of 1200 or less, more typically1100 or less, more typically 1050 or less, and most typically about1000. The polymer electrolyte membrane may be cast, coated or otherwiseformed from a suspension. Any suitable method of coating or casting maybe used, including bar coating, spray coating, slit coating, brushcoating, and the like. Membrane 110 is typically 100 micrometers inthickness or less, more typically 50 micrometers in thickness or less,and more typically 30 micrometers in thickness or less.

[0018] Any suitable vacuum conveyors may be used. Angled vacuumconveyors 30, 40 comprise endless perforated belts 120 perforated withbelt holes 121. The belt may be made of any suitable material, includingpolymers, rubbers, fabrics, composites, and the like, provided that theouter surface is compatible with workpiece 110 to be transported on thebelt. Endless perforated belt 120 passes over first vacuum plate 130having longitudinal openings, not shown, and second vacuum plate 140having longitudinal openings, not shown. Belt holes 121 are arranged inrows aligned with the longitudinal openings. Typically, each vacuumplate 130, 140 has at least two longitudinal openings aligned with atleast two rows of belt holes 121. More typically, each vacuum plate 130,140 has four or more longitudinal openings aligned with four or morerows of belt holes 121, so as to enable the vacuum conveyor to gripworkpieces 100 of varying sizes across the majority of their width. Inthe embodiment as depicted, endless perforated belts 120 are driven in adirection toward the vacuum plate which angles downward for delivery ofthe workpiece 100 to laminating station 50.

[0019] Longitudinal openings in first and second vacuum plates 130, 140communicate with first and second vacuum chambers (not shown),respectively. First and second vacuum chambers are maintained at firstand second sub-ambient air pressures, such that the sub-ambient airpressures tend to hold workpiece 100 to endless perforated belt 120.First and second sub-ambient air pressures may be the same or different.Where first and second sub-ambient air pressures are different, thefirst sub-ambient air pressure is typically less than the second,enabling the conveyor to better hold workpieces 100 coming onto theconveyor at locations over first vacuum plate 130 and release workpiecesleaving the conveyor from locations over second vacuum plate 140. Thefirst and second vacuum chambers are maintained at first and secondsub-ambient air pressures by any suitable means. The vacuum chambers maybe functionally connected to one or more sources of sub-ambient airpressure such as vacuum pumps and the like.

[0020] First vacuum plate 130 is situated at a first angle relative tohorizontal, which is approximately 0°. Second vacuum plate 140 issituated at second angle relative to horizontal, which is approximately−45°. Typically, the first and second angles are not equal. Typically,the first angle is between 30° and −30° relative to horizontal and saidsecond angle is between −30° and −90° relative to horizontal. Moretypically, the first angle is between 5° and −5° relative to horizontaland said second angle is between −40° and −50° relative to horizontal.These angles allow angled vacuum conveyors 30, 40, to receive workpieces100 from rotary die stations 10, 20, and deliver workpieces 100 downwardinto the laminating nip of lamination station 50.

[0021] First and second vacuum plates 130, 140 are mounted to a framemade up of one or more frame elements 150. Endless perforated belt 120passes over a number of rollers rotatably mounted to frame elements 150.Endless perforated belt 120 also passes through drive mechanism 160powered by servo motor 170.

[0022] In the place of vacuum conveyors, any positive grip conveyor mayalternately be used. Positive grip conveyors may include knownpick-and-place mechanisms, including those comprising armaturemechanisms, known two-belt conveyors, which employ a pair of belts toform an extended nip to convey a workpiece, and known static electricityconveyors which hold a workpiece to a endless belt by the use of astatic electric charge. Vacuum conveyors are advantageously used forhandling delicate workpieces.

[0023] Lamination station 50 comprises first laminating roller 180 andsecond laminating roller 190. Either or both of first laminating roller180 and second laminating roller 190 may be driven by known means suchas motors and the like. Typically both are driven. Typically firstlaminating roller 180 and second laminating roller 190 are gearedtogether so that they have the same speed at the gap. In one embodiment,first laminating roller 180 and second laminating roller 190 are drivenby servo motor 200 which drives belt 201 and pulleys 202, 203. A belttensioning system, not shown, maintains bend 204.

[0024] Typically first laminating roller 180 and second laminatingroller 190 ride in bearings 210, which are of known types such as ballbearings, roller bearings, needle bearings, and the like. Bearings 210are attached to the apparatus frame 220 such that pressure can bebrought or maintained on bearings 210 which tends to bring togetherfirst and second laminating rollers 180, 190. The bearing housings maybe fixedly attached to frame 220 or attached by means of pneumatic orhydraulic pistons and cylinders 230, as shown. Bearing mechanisms mayform a part of drive mechanisms for either or both rollers.

[0025] First laminating roller 180 and second laminating roller 190 maybe heated by any suitable method but are typically internally heated bya method such as electrical heating or circulation of hot air, water oroil.

[0026] Typically, a minimum laminating gap is maintained between firstlaminating roller 180 and second laminating roller 190. This minimumlaminating gap is typically maintained by use of the gapping blockdescribed in co-pending U.S. patent application ______, titled “GapAdjuster for Laminating Rolls,” filed on even date herewith. Bymaintaining a minimum gap in this manner, the apparatus according to thepresent invention may be used for intermittent lamination, i.e., whereone or more of the layers to be laminated is not continuously present inthe laminating gap during lamination. In that case, the product may be acontinuous web with non-continuous patches of additional sheet materialslaminated thereto. In the case of intermittent lamination, thecontinuous web could be crushed or damaged if the full laminatingpressure were applied when the non-continuous sheet material was notpresent in the gap.

[0027] Typically, webs of laminating cover liner are introduced oneither side of the laminating nip during lamination, so that firstlaminating roller 180 and second laminating roller 190 are covered by afirst laminating cover liner and a second laminating cover liner,respectively, during lamination. The use of laminating cover liners mayenable higher temperature lamination. After lamination, first and secondlaminating cover liners are removed from the laminate and rewound. Anysuitable material may be used for first and second laminating coverliners, so long as the material will not become laminated under thelaminating conditions and will not impart any undesirable texture to thelaminate.

[0028] Angled vacuum conveyors 30, 40 and rotary die stations 10, 20 areadvantageously arranged such that an emerging portion of a workpiece 100being cut from a web of workpiece material can become held by the actionof the first sub-ambient pressure in the first vacuum chamber, drawingair through first vacuum plate 130 and endless perforated belt 120,before workpiece 100 is fully separated from the web of workpiecematerial. Angled vacuum conveyors 30, 40 and laminating station 50 areadvantageously arranged such that a leading edge of a workpiece 100being transported by an angled vacuum conveyor 30, 40 is drawn into thelaminating nip of lamination station 50 before it is fully released bythe angled vacuum conveyor 30, 40. Most advantageously, botharrangements are made, so that workpiece 100 is held by angled vacuumconveyors 30, 40 before workpiece 100 is fully separated from the web ofworkpiece material and workpiece 100 is drawn into the laminating nip oflamination station 50 before it is fully released by the angled vacuumconveyor 30, 40. In this way, positive control of workpiece location ismaintained through every step. As a result, membrane 110 may belaminated on both sides with accurate registration. Accurateregistration typically means that the perimeters of the pattern-cutsheet materials match to within 2 mm, more typically 1 mm, moretypically 0.5 mm, more typically 250 μm, and more typically 125 μm.

[0029] Drive mechanisms for rotary die stations 10, 20, angled vacuumconveyors 30, 40, and lamination station 50 are advantageously geared orsynchronized together, by mechanical or more typically by electronicgearing. The drive mechanism for propelling endless perforated belt 120may be geared with the drive mechanism driving rotary die 60 such thatthe linear surface velocity of endless perforated belt 120 may be equalto or greater than the linear surface velocity of rotary die 60. Agreater velocity enables the conveyor to space apart workpieces 100 asthey emerge from rotary die 60, so that workpieces 100 may be cut withno intervening scrap but placed with intervening margins. The drivemechanism for propelling endless perforated belt 120 may be geared withthe drive mechanism driving first and second laminating rollers 180, 190such that the linear surface velocity of first and second laminatingrollers 180, 190 may be equal to or greater than the linear surfacevelocity of endless perforated belt 120.

[0030] In the method according to the present invention, a membrane 110such as a web of polymer electrolyte membrane material is drawn betweenlaminating rollers 180, 190 in laminating station 50 which form alaminating nip. A first and second web of laminate material is die-cutat rotary die stations 10, 20 to form cut workpieces 100. The first andsecond webs of laminate material may be the same or different. The firstand second webs of laminate material may be catalyst decal materialscomprising a liner layer and a first catalyst layer, or electrodematerial comprising a fluid transport layer and a first catalyst layer.The cut workpieces 100 are transported to laminating station 50 byvacuum conveyors 30 and 40 and concurrently fed into the laminating nipbetween laminating rollers 180 and 190 on either side of membrane 110 toform a laminate. Advantageously, workpieces 100 come to be held byaction of sub-ambient air pressure to vacuum conveyors 30 and 40 beforethey are completely separated from first or second webs of laminatematerial. Advantageously workpieces 100 are gripped by the laminatingnip between laminating rollers 180 and 190 before they are released fromvacuum conveyors 30 and 40.

[0031] The lamination may be repeated to form a continuous web ofmembrane linking similar laminates.

[0032] Where membrane 110 is a polymer electrolyte membrane, asdescribed above, and workpieces 100 are catalyst decals, as describedabove, the method and apparatus according to the present invention maybe used to produce a continuous membrane that comprises a plurality ofmembrane electrode assemblies, all comprising first and second patternedcatalyst layer segments which are in accurate registration. The firstand second patterned catalyst layer segments can have a perimeter whichis a shape other than a four-sided parallelogram. Typical die-cut shapeshave rounded corners, and may additionally form any of a large number ofarbitrary perimeter shapes. The first and second patterned catalystlayer segments can have the same or different catalyst composition.

[0033] Where membrane 110 is a polymer electrolyte membrane, asdescribed above, and workpieces 100 are electrodes comprising a fluidtransport layer and a co-extensive catalyst layer catalyst decals, asdescribed above, the method and apparatus according to the presentinvention may be used to produce a continuous membrane that comprises aplurality of membrane electrode assemblies, all comprising first andsecond patterned electrode segments which are in accurate registration.The first and second patterned electrode segments can have a perimeterwhich is a shape other than a four-sided parallelogram. Typical die-cutshapes have rounded corners, and may additionally form any of a largenumber of arbitrary perimeter shapes. The first and second patternedelectrode segments can have the same or different catalyst composition.

[0034] Various modifications and alterations of this invention willbecome apparent to those skilled in the art without departing from thescope and principles of this invention, and it should be understood thatthis invention is not to be unduly limited to the illustrativeembodiments set forth hereinabove. All publications and patents areherein incorporated by reference to the same extent as if eachindividual publication or patent was specifically and individuallyindicated to be incorporated by reference.

We claim:
 1. A die-cut catalyst decal comprising a liner layer and aco-extensive catalyst layer, said catalyst layer comprising particulatecatalyst metal, wherein said decal has a perimeter which is a shapeother than a four-sided parallelogram.
 2. A die-cut electrode comprisinga fluid transport layer and a co-extensive catalyst layer, said catalystlayer comprising particulate catalyst metal, wherein said electrode hasa perimeter which is a shape other than a four-sided parallelogram.
 3. Amethod of making a die-cut catalyst decal according to claim 1 whichcomprises die-cutting a web of catalyst decal material, said webcomprising a liner layer and a catalyst layer.
 4. The method accordingto claim 3 wherein said step of die-cutting comprises rotarydie-cutting.
 5. A method of making a die-cut electrode according toclaim 2 which comprises die-cutting a web of electrode material, saidweb comprising a fluid transport layer and a catalyst layer.
 6. Themethod according to claim 5 wherein said step of die-cutting comprisesrotary die-cutting.
 7. A membrane comprising a plurality of membraneelectrode assemblies, which comprises: a polymer electrolyte membranehaving a first and second face; a plurality of first patterned catalystlayer segments laminated on said first face of said membrane such thatadjacent patterned catalyst layer segments are not in contact with eachother; and a plurality of second patterned catalyst layer segmentslaminated on said second face of said membrane such that adjacentpatterned catalyst layer segments are not in contact with each other;wherein each of said first patterned catalyst layer segments has aperimeter and each of said second patterned catalyst layer segments hasa perimeter which is in accurate registration with a perimeter of anopposing first patterned catalyst layer segment.
 8. A continuous webcontaining a plurality of membrane electrode assemblies which comprises:a polymer electrolyte membrane having a first and second face; aplurality of first patterned catalyst layer segments laminated on saidfirst face of said membrane such that adjacent patterned catalyst layersegments are not in contact with each other; and a plurality of secondpatterned catalyst layer segments laminated on said second face of saidmembrane such that adjacent patterned catalyst layer segments are not incontact with each other; wherein each of said first and second patternedcatalyst layer segments have a perimeter which is a shape other than afour-sided parallelogram.
 9. The continuous web according to claim 7wherein each of said first and second patterned catalyst layer segmentshave a perimeter which is a shape other than a four-sided parallelogram.10. The continuous web according to claim 7 wherein said first catalystlayer segments have a first catalyst composition and said secondcatalyst layer segments have a second catalyst composition that differsfrom said first catalyst composition.
 11. The continuous web accordingto claim 8 wherein said first catalyst layer segments have a firstcatalyst composition and said second catalyst layer segments have asecond catalyst composition that differs from said first catalystcomposition.
 12. The continuous web according to claim 9 wherein saidfirst catalyst layer segments have a first catalyst composition and saidsecond catalyst layer segments have a second catalyst composition thatdiffers from said first catalyst composition.
 13. A membrane comprisinga plurality of membrane electrode assemblies, which comprises: a polymerelectrolyte membrane having a first and second face; a plurality offirst patterned electrode layer segments laminated on said first face ofsaid membrane such that adjacent patterned electrode layer segments arenot in contact with each other, each first patterned electrode segmentcomprising a fluid transport layer and a co-extensive layer of a firstcatalyst; and a plurality of second patterned electrode layer segmentslaminated on said second face of said membrane such that adjacentpatterned electrode layer segments are not in contact with each other,each second patterned electrode segment comprising a fluid transportlayer and a co-extensive layer of a second catalyst; wherein each ofsaid first patterned electrode layer segments has a perimeter and eachof said second patterned electrode layer segments has a perimeter whichis in accurate registration with a perimeter of an opposing firstpatterned electrode layer segment.
 14. A membrane comprising a pluralityof membrane electrode assemblies, which comprises: a polymer electrolytemembrane having a first and second face; a plurality of first patternedelectrode layer segments laminated on said first face of said membranesuch that adjacent patterned electrode layer segments are not in contactwith each other, each first patterned electrode segment comprising afluid transport layer and a co-extensive layer of a first catalyst; anda plurality of second patterned electrode layer segments laminated onsaid second face of said membrane such that adjacent patterned electrodelayer segments are not in contact with each other, each second patternedelectrode segment comprising a fluid transport layer and a co-extensivelayer of a second catalyst; wherein each of said first and secondpatterned electrode layer segments have a perimeter which is a shapeother than a four-sided parallelogram.
 15. The continuous web accordingto claim 13 wherein each of said first and second patterned electrodesegments have a perimeter which is a shape other than a four-sidedparallelogram.
 16. The continuous web according to claim 13 wherein saidfirst catalyst has a first catalyst composition and said second catalysthas a second catalyst composition that differs from said first catalystcomposition.
 17. The continuous web according to claim 14 wherein saidfirst catalyst has a first catalyst composition and said second catalysthas a second catalyst composition that differs from said first catalystcomposition.
 18. The continuous web according to claim 15 wherein saidfirst catalyst has a first catalyst composition and said second catalysthas a second catalyst composition that differs from said first catalystcomposition.
 19. A method of making a membrane electrode assemblycomprising the steps of: a) providing a web of polymer electrolytemembrane material; b) providing a laminating station wherein said web ofpolymer electrolyte membrane material is drawn between a pair oflaminating rollers which form a laminating nip; c) die-cutting a firstweb of first catalyst decal material, said web comprising a liner layerand a first catalyst layer, to make a first catalyst decal; d)die-cutting a second web of second catalyst decal material, said webcomprising a liner layer and a second catalyst layer, to make a secondcatalyst decal; e) transporting said first catalyst decal to saidlaminating station; f) transporting said second catalyst decal to saidlaminating station; g) feeding said first catalyst decal into saidlaminating nip adjacent to said web of polymer electrolyte membranematerial; h) feeding said second catalyst decal into said laminating nipadjacent to said web of polymer electrolyte membrane materialconcurrently with said first catalyst decal; i) laminating said firstcatalyst decal, said web of polymer electrolyte membrane material andsaid second catalyst decal to form a laminate.
 20. A method of making acontinuous web according to claim 7 comprising the method of claim 19,additionally comprising the step of: l) repeating steps a)-i).
 21. Themethod according to claim 19 additionally comprising the steps of: m)holding said first catalyst decal by action of sub-ambient air pressureto an endless perforated belt of a vacuum conveyor before step c) iscomplete; and n) beginning step g) before releasing said first catalystdecal from said endless perforated belt of said vacuum conveyor.
 22. Themethod according to claim 21 additionally comprising the steps of: o)holding said second catalyst decal by action of sub-ambient air pressureto an endless perforated belt of a vacuum conveyor before step d) iscomplete; and p) beginning step h) before releasing said second catalystdecal from said endless perforated belt of said vacuum conveyor.
 23. Amethod of making a membrane electrode assembly comprising the steps of:a) providing a web of polymer electrolyte membrane material; b)providing a laminating station wherein said web of polymer electrolytemembrane material is drawn between a pair of laminating rollers whichform a laminating nip; c) die-cutting a first web of first electrodematerial, said web comprising a fluid transport layer and a firstcatalyst layer, to make a first electrode; d) die-cutting a second webof second electrode material, said web comprising a fluid transportlayer and a second catalyst layer, to make a second electrode; e)transporting said first electrode to said laminating station; f)transporting said second electrode to said laminating station; g)feeding said first electrode into said laminating nip adjacent to saidweb of polymer electrolyte membrane material; h) feeding said secondelectrode into said laminating nip adjacent to said web of polymerelectrolyte membrane material concurrently with said first electrode; i)laminating said first electrode, said web of polymer electrolytemembrane material and said second electrode to form a laminate.
 24. Amethod of making a continuous web according to claim 13 comprising themethod of claim 23, additionally comprising the step of: l) repeatingsteps a)-i).
 25. The method according to claim 23 additionallycomprising the steps of: m) holding said first electrode by action ofsub-ambient air pressure to an endless perforated belt of a vacuumconveyor before step c) is complete; and n) beginning step g) beforereleasing said first electrode from said endless perforated belt of saidvacuum conveyor.
 26. The method according to claim 25 additionallycomprising the steps of: o) holding said second electrode by action ofsub-ambient air pressure to an endless perforated belt of a vacuumconveyor before step d) is complete; and p) beginning step h) beforereleasing said second electrode from said endless perforated belt ofsaid vacuum conveyor.
 27. An apparatus for making a membrane electrodeassembly comprising: a) a lamination station; b) a first and secondvacuum conveyor; and c) a first and second rotary die station.
 28. Theapparatus according to claim 27 wherein said first vacuum conveyor andsaid first rotary die station are arranged such that, with said firstvacuum conveyor and said first rotary die station both functioning, anemerging portion of a workpiece being cut from a first web of workpiecematerial in said first rotary die station will become held by said firstvacuum conveyor before said workpiece is fully separated from said firstweb of workpiece material.
 29. The apparatus according to claim 28wherein said first vacuum conveyor and said lamination station arearranged such that, with said first vacuum conveyor and said laminationstation both functioning, said workpiece is drawn into a laminating nipof said lamination station before it is fully released by said firstvacuum conveyor.
 30. The apparatus according to claim 29 wherein saidfirst vacuum conveyor comprises a first endless perforated belt having alinear surface velocity and a first vacuum conveyor drive mechanismfunctionally connected thereto, wherein said first rotary die stationcomprises a first rotary die having a linear surface velocity and afirst rotary die station drive mechanism functionally connected thereto,wherein said first vacuum conveyor drive mechanism and said first rotarydie station drive mechanism are geared together such that the linearsurface velocity of said first endless perforated belt is greater thanthe linear surface velocity of said first rotary die.
 31. The apparatusaccording to claim 30 wherein said lamination station comprises firstand second laminating rollers having a common linear surface velocityand a laminating drive mechanism functionally connected thereto, whereinsaid first vacuum conveyor drive mechanism and said laminating drivemechanism are geared together such that the linear surface velocity ofsaid first endless perforated belt is equal to the linear surfacevelocity of said first and second laminating rollers.
 32. The apparatusaccording to claim 31 wherein said second vacuum conveyor and saidsecond rotary die station are arranged such that, with said secondvacuum conveyor and said second rotary die station both functioning, anemerging portion of a workpiece being cut from a second web of workpiecematerial in said second rotary die station will become held by saidsecond vacuum conveyor before said workpiece is fully separated fromsaid second web of workpiece material.
 33. The apparatus according toclaim 32 wherein said second vacuum conveyor and said lamination stationare arranged such that, with said second vacuum conveyor and saidlamination station both functioning, said workpiece is drawn into alaminating nip of said lamination station before it is fully released bysaid second vacuum conveyor.
 34. The apparatus according to claim 33wherein said second vacuum conveyor comprises a second endlessperforated belt having a linear surface velocity and a second vacuumconveyor drive mechanism functionally connected thereto, wherein saidsecond rotary die station comprises a second rotary die having a linearsurface velocity and a second rotary die station drive mechanismfunctionally connected thereto, wherein said second vacuum conveyordrive mechanism and said second rotary die station drive mechanism aregeared together such that the linear surface velocity of said secondendless perforated belt is greater than the linear surface velocity ofsaid second rotary die.
 35. The apparatus according to claim 34 whereinsaid second vacuum conveyor drive mechanism and said laminating drivemechanism are geared together such that the linear surface velocity ofsaid second endless perforated belt is equal to the linear surfacevelocity of said first and second laminating rollers.
 36. An apparatusfor making a membrane electrode assembly comprising: a) a laminationstation; b) a first and second positive grip conveyor; and c) a firstand second rotary die station.
 37. The apparatus according to claim 36wherein said first positive grip conveyor and said first rotary diestation are arranged such that, with said first positive grip conveyorand said first rotary die station both functioning, an emerging portionof a workpiece being cut from a first web of workpiece material in saidfirst rotary die station will become held by said first positive gripconveyor before said workpiece is fully separated from said first web ofworkpiece material.
 38. The apparatus according to claim 37 wherein saidfirst positive grip conveyor and said lamination station are arrangedsuch that, with said first positive grip conveyor and said laminationstation both functioning, said workpiece is drawn into a laminating nipof said lamination station before it is fully released by said firstpositive grip conveyor.